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These digital transcripts are meant to share information on process safety practices in order to help improve process safety performance and awareness throughout industry. The goal is to capture and share knowledge that could be used by other companies or sites when developing new process safety practices or improving existing ones. The documents being shared have been used by an industry member, but this does not mean it should be used or that it will produce similar results at any other site. Rather, it is an option to consider when implementing or adjusting programs and practices at a site. ​

BY THEMSELVES, THESE DIGITAL TRANSCRIPTS ARE NOT STANDARDS OR RECOMMENDED PRACTICES. THEY ARE NOT INTENDED TO REPLACE SOUND ENGINEERING JUDGMENT. THEY DO NOT PRECLUDE THE USE OF ALTERNATIVE METHODS THAT COMPLY WITH LEGAL REQUIREMENTS. A SUBJECT MATTER EXPERT SHOULD BE CONSULTED PRIOR TO DETERMINING WHETHER A PRACTICE CAN BE USED IN ANY SPECIFIC SITUATION. 

​

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Process

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(2015) Question 90: We are planning to purchase a new flue gas steam generator. What is your preferred configuration? What are the critical operating parameters you employ to ensure reliable operation? What is your sparing philosophy?

The configuration of the flue gas steam generator will be predominantly governed by FCC design. For a partial-combustion unit, it will be a CO boiler or a CO incinerator cum FGC (flue gas cooler) combination. For complete combustion, it will be a FGC or waste heat boiler alone. By CO boiler, typically we mean a boiler where the steam generating tubes are exposed to direct flame.
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(2015) Question 91: What are your top three causes of unit slowdowns, and what is the loss in onstream factor for each? Please provide the same information for your top three causes of unit shutdowns.

FCC/RFCC units are the one of the major secondary units in almost all of IOCL’s refineries. Irrespective of demand positions, these units are always required to operate at high capacities. All of our refineries had been participating in the benchmarking surveys conducted by Solomon Associates, and the results comparing IOCL FCC units with rest of the world (2014 study) are indicated below.
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